<p dir="ltr" id="isPasted">Did you know that injection molding is transforming the medical device industry? This advanced process empowers designers to create high-quality and cost-effective products, ranging from common medical items to highly regulated devices. As products move through various stages of development—from initial prototyping to full-scale production—they must consistently meet stringent compliance, safety, and functionality standards. This ensures that each medical device aligns with critical industry requirements at every step.</p><p dir="ltr">If you’re considering taking the next step in medical injection molding, this article will guide you through 4 key considerations in medical injection molding, from understanding device classifications and regulations to selecting suitable materials and preparing your design.</p><h2 dir="ltr">Key Considerations in Medical Injection Molding</h2><h3 dir="ltr">1. Regulatory Compliance: Meeting Corresponding Standards</h3><p dir="ltr">&nbsp;Food and Drug Administration (FDA) guidelines in the U.S. mandate rigorous tracking and documentation at every production stage to guarantee the traceability of each component. Meanwhile, Medical Device Regulation (MDR) standards in the EU emphasize consistent product safety across the device’s entire lifecycle, pushing manufacturers to follow stringent standards.</p><p dir="ltr">Medical devices are divided into three classifications, by both FDA and MDR, based on associated risk, each with specific regulatory requirements:</p><p dir="ltr"><strong>Class I Medical Devices: </strong>These low-risk devices pose minimal harm to users, often including items like bandages, gloves, and hand-held surgical instruments. Regulatory requirements are relatively basic, focusing mainly on general safety and quality.</p><p dir="ltr"><strong>Class II Medical Devices: </strong>Moderate-risk devices, such as syringes, infusion pumps, and diagnostic equipment, require additional regulatory controls. These may involve special labeling, performance standards, and post-market supervision.</p><p dir="ltr"><strong>Class III Medical Devices:</strong> High-risk devices, including pacemakers, defibrillators, and implants, require the highest level of regulatory supervision. This includes rigorous premarket approval, extensive testing, and clinical trials to confirm safety and effectiveness.</p><p dir="ltr">For instance, a diagnostic device used for detecting infectious diseases needs each plastic component to withstand various sterilization processes without degrading or releasing harmful substances. Even minor contamination could compromise the device’s accuracy or pose risks to patients, underscoring the importance of these strict regulatory standards. Ensuring regulatory compliance is essential in medical injection molding, as incorrect categorization or non-compliance can lead to delays, increased costs, and a longer time to market.</p><h3 dir="ltr">2. Certifications: Guaranteeing Quality and Safety</h3><p dir="ltr">Certification is a standard, ensuring the products meet or exceed industry requirements. Key certifications in the medical industry include:</p><p dir="ltr"><strong>ISO 13485: </strong>This certification ensures a quality management system is in place, maintaining consistency across production batches. For example, if producing IV systems or ventilators, ISO 13485 certification is critical.</p><p dir="ltr"><strong>ISO 10993: </strong>For parts that come in direct contact with bodily fluids or tissues, ISO 10993 ensures biocompatibility. This certification is essential when manufacturing parts such as catheter tips or implantable device housings, where material safety directly impacts patient health.</p><p dir="ltr"><strong>ISO 14644: </strong>This cleanroom certification is crucial for preventing contamination. A cleanroom-certified facility, for instance, can safely produce surgical device components that require a sterile environment, ensuring they meet hospital and surgical standards.</p><h3 dir="ltr">3. Material Selection: Biocompatibility and Durability</h3><p dir="ltr">Choosing materials for medical applications involves considerations beyond standard injection molding. Examples include:</p><ul><li dir="ltr"><p dir="ltr"><strong>Polycarbonate (PC):</strong> Due to its strength and transparency, often used for housing devices requiring internal visibility, such as blood analyzers.</p></li><li dir="ltr"><p dir="ltr"><strong>Polyethylene (PE):&nbsp;</strong>Known for chemical resistance and flexibility, PE is used in IV bags and tubing, ensuring durability and low moisture absorption.</p></li><li dir="ltr"><p dir="ltr"><strong>Polypropylene (PP):</strong> With strong impact resistance and sterilization stability, PP is used in syringes and medical containers, offering long-term reliability.</p></li><li dir="ltr"><p dir="ltr"><strong>Polystyrene (PS):&nbsp;</strong>Widely used for disposable labware, PS offers rigidity, transparency, and easy sterilization, making it suitable for laboratory applications.</p></li><li dir="ltr"><p dir="ltr"><strong>Polyether Ether Ketone (PEEK):&nbsp;</strong>Widely used in implantable devices due to its strength, stability under sterilization, and biocompatibility.</p></li><li dir="ltr"><p dir="ltr"><strong>Thermoplastic Elastomer (TPE):&nbsp;</strong>Its flexibility makes it suitable for soft-touch surgical instrument handles that withstand repeated sterilization.</p></li></ul><p dir="ltr">Every material choice has specific trade-offs. For instance, while PE and PP are cost-effective and chemically resistant, they might lack the strength needed for parts exposed to high-stress environments. Therefore, understanding these nuances helps in material selection, optimizing for both performance and cost.<a href="https://www.rpworld.com/en/resources/blog/what-materials-work-best-for-your-medical-device-development.html">&nbsp;Click Here</a> to explore more material choices.</p><h3 dir="ltr">4. Prototyping to Production: Ensuring a Smooth Transition</h3><p dir="ltr">Transitioning from prototypes to full-scale production isn’t always straightforward. During prototyping, designs may feature thinner walls or more complex geometries than standard injection molding processes can easily reproduce at scale. For example, a prototype with sharp corners that’s achievable created by the vacuum casting process, but requires design optimization, such as adding radii, and adding draft angle for efficient injection molding without sacrificing quality.</p><p dir="ltr">When scaling up, an experienced injection molding partner with expertise and capabilities can help optimize these designs for manufacturability without compromising on quality. At RPWORLD, we assist clients in this crucial transition, helping optimize part design, select the most suitable materials, finishing options and more to support efficient and regulatory-compliant production.</p><h2 dir="ltr">How RPWORLD Injection Molding Accelerates Your Medical Development</h2><p dir="ltr">At RPWORLD, we integrate material expertise, one-stop manufacturing services, in-depth DFM analysis and ISO-certified process to help bring medical devices to market faster. Our services cover the entire lifecycle—from prototyping to mass production—tailoring to meet the unique needs of each medical device.</p><p dir="ltr">Our Injection Molding Services Include:</p><ul><li dir="ltr"><p dir="ltr">20+ years of experience in medical device injection molding, from prototyping to end-use production.</p></li><li dir="ltr"><p dir="ltr">Mold flow analysis, and in-house tools design and fabrication.</p></li><li dir="ltr"><p dir="ltr">Design for Manufacturing (DFM) guidance, including design optimization, material selection, finishing selection and more to avoid costly rework and save time up to 80%.</p></li><li dir="ltr"><p dir="ltr">A wide variety of post-processing options to perfect your parts.</p></li><li dir="ltr"><p dir="ltr">State-of-the-art quality inspection equipment and stringent quality control including real-time process monitoring to ensure consistency.</p></li></ul>

Photo by National Cancer Institute on Unsplash

If you’re considering taking the next step in medical injection molding, this article will guide you through 4 key considerations in medical injection molding, from understanding device classifications and regulations to selecting suitable materials and preparing your design.

From Prototype to Production - 4 Critical Considerations for Safe and Compliant Medical Injection Molding

<p id="isPasted"><a href="https://www.apsx.com/" target="_blank" rel="noopener noreferrer">APSX machines</a> provide a strategic advantage for manufacturers looking to achieve sustainability and cater to small-batch production, particularly for niche markets. Here’s how they contribute to these areas:</p><p><strong>1. Sustainability through Resource Optimization</strong></p><p>APSX machines are engineered to support sustainable manufacturing practices by incorporating features that minimize resource consumption and waste generation. Here are the key aspects that enhance sustainability:</p><ul type="disc"><li><strong>Precision Engineering with Minimal Waste:</strong> APSX machines employ advanced CNC machining techniques and high-precision controls that optimize material usage. These machines reduce excess material usage, leading to less waste and more efficient use of raw materials.</li><li><strong>Energy-Efficient Operations:</strong> The machines are equipped with energy-efficient drives and smart motor controls that reduce power consumption during idle periods and optimize energy use during production. This efficiency lowers the overall carbon footprint of manufacturing processes.</li><li><strong>Reduced Tooling and Maintenance Requirements:</strong> APSX machines often require fewer tool changes and less maintenance compared to traditional manufacturing setups. This results in a lower consumption of consumables and extends the lifespan of parts, contributing to less industrial waste and a more sustainable production environment.</li><li><strong>Support for Eco-Friendly Materials:</strong> These machines can handle a wide range of materials, including biodegradable and recycled composites, supporting the use of eco-friendly alternatives. Manufacturers can experiment with sustainable materials without compromising on quality or precision.</li></ul><p><strong>2. Small-Batch Production for Niche Markets</strong></p><p>APSX machines are particularly well-suited for small-batch production, making them an ideal solution for niche markets that demand high customization and lower production volumes. Here’s how APSX machines help:</p><ul type="disc"><li><strong>Flexible Production Capabilities:</strong> APSX machines are designed with versatility in mind, allowing manufacturers to quickly switch between different product configurations without the need for extensive retooling. This flexibility is crucial for producing small batches of customized products or catering to specific client requirements.</li><li><strong>Cost-Effective for Low-Volume Runs:</strong> Traditional manufacturing equipment often incurs high setup costs, making small-batch production economically unfeasible. APSX machines, with their lower upfront costs, modular configurations, and minimal setup requirements, enable manufacturers to achieve profitability even with low-volume runs.</li><li><strong>Shorter Lead Times:</strong> With advanced CNC and additive manufacturing capabilities, APSX machines reduce production times and enable rapid prototyping, making it easier to test and validate new designs. This agility is essential for niche markets that value speed and flexibility in meeting unique customer needs.</li><li><strong>Customization with High Precision:</strong> Niche markets often require highly specialized products with unique specifications. APSX machines can execute complex geometries and fine detailing with high accuracy, ensuring that even small production runs meet the exact standards of quality and design.</li></ul><p><strong>3. Supporting Sustainable Product Development</strong></p><p>APSX machines allow businesses to experiment and iterate on sustainable product designs with minimal material investment. This makes it easier for companies to refine eco-friendly product offerings without incurring the high costs typically associated with traditional prototyping and production methods. For manufacturers targeting environmentally-conscious markets, this capability supports the development of products that align with sustainability goals.</p><p><strong>4. Enabling On-Demand Manufacturing</strong></p><p>In niche markets, demand can be unpredictable and fluctuate widely. APSX machines enable an on-demand manufacturing model, where production is initiated based on real-time orders rather than maintaining high levels of inventory. This approach minimizes overproduction and reduces inventory waste, further contributing to sustainable practices.</p><p>#injectionmolding #cncmachining #prototyping #sustainability&nbsp;</p>

APSX machines provide a strategic advantage for manufacturers looking to achieve sustainability and cater to small-batch production, particularly for niche markets.

Sustainability and Small-Batch Production with APSX Machines

<p id="isPasted">From accelerating production timelines to ensuring unmatched quality control, the adoption of APSX machines can redefine operational performance for businesses of all sizes from an inventor/entrepreneur alone to global companies around the world.</p><p><strong>1. Revolutionizing Manufacturing Efficiency with Automation</strong></p><p>APSX machines are built with automation at their core, reducing manual intervention and optimizing every stage of production. They incorporate CNC capabilities, allowing for precise execution of complex parts and simple injection molding process for making real plastic functional parts instead of fragile 3D printed parts. This translates into shorter production cycles, lower lead times, and a dramatic reduction in product development and production costs.</p><p>By integrating APSX machinery, businesses can achieve substantial efficiency gains, minimizing downtime due to long lead times and ensuring continuous production. These systems also enable manufacturers to schedule operations 24/7, maximizing output and enhancing the overall production capacity without compromising quality.</p><p><strong>2. Scalable Solutions Tailored for SMEs</strong></p><p>For small and medium enterprises (SMEs), balancing capital investment with production output is critical. APSX machines provide a cost-efficient solution, featuring modular designs that scale with business growth. Unlike traditional machinery, APSX systems have a low total cost of ownership (TCO), owing to their energy-efficient operations, minimal maintenance requirements, and a reduced need for expensive tooling.</p><p>This scalability ensures that SMEs can start with a smaller setup and expand their manufacturing capabilities as demand increases, without the need for a complete overhaul of their production infrastructure. The flexibility and affordability of APSX solutions make them ideal for companies looking to innovate while maintaining profitability.</p><p><strong>3. Enhanced Versatility Across Multiple Sectors</strong></p><p>One of the standout features of APSX machinery is its adaptability to various manufacturing needs. From automotive components to medical device production, these machines are engineered to handle a broad spectrum of materials, including metals, plastics, and composites. This versatility is supported by advanced programming options and customizable mold designs that allow for seamless transitions between different product specifications.</p><p>For industries requiring precision and consistency—such as aerospace and electronics manufacturing—APSX machines provide unparalleled control over complex geometries and intricate detailing, ensuring that each output meets stringent industry standards.</p><p><strong>4. Accelerated Prototyping for Rapid Product Development</strong></p><p>In today’s competitive market, speed-to-market is a critical success factor. APSX machines empower businesses to rapidly prototype new designs using subtractive and additive manufacturing techniques. By leveraging CNC milling or 3D printing capabilities, companies can iterate quickly on product designs, making necessary adjustments in a fraction of the time required by traditional methods.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1727718506442-27.09.2024_12.21.09_REC.png" style="width: 100%px;" class="fr-fic fr-dib"></p><p>This rapid prototyping capability reduces the time between concept and market-ready product, enabling manufacturers to respond swiftly to consumer feedback and changing market trends. Moreover, the ability to produce functional prototypes allows for comprehensive testing, ensuring that final products meet all performance and reliability criteria before mass production.</p><p><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzI3NzE4MzI0NTY1LUFQU1gtUElNX0hvbWVQYWdlXzEwMDAuSlBHIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib"></p><p><strong>5. Precision Engineering for Superior Product Quality</strong></p><p>Precision and repeatability are the hallmarks of APSX machinery. Using state-of-the-art software and premium components, these machines deliver exceptional accuracy, maintaining tight dimensional control even in high-volume production runs. This capability is essential for industries where product uniformity and reliability are non-negotiable, such as medical device manufacturing and precision engineering.</p><p>APSX machines utilize closed-loop feedback systems, ensuring real-time adjustments that prevent deviations and guarantee that each part produced is identical to the next. This high degree of precision reduces the incidence of defective products, enhances quality assurance, and minimizes material waste, ultimately leading to improved profitability and sustainability.</p><p><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzI3NzE4MzUwODEwLXN3aXNzLWJhbm5lcl8xLnBuZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib"></p><p><strong>6. Sustainability Through Resource Efficiency</strong></p><p>Environmental responsibility is becoming a priority for manufacturers worldwide. APSX machines contribute to sustainability by incorporating energy-efficient drives and low-waste manufacturing techniques. With programmable precision, these machines optimize material usage, minimizing scrap rates and reducing the overall carbon footprint of the production process.</p><p>In addition, the adoption of APSX technology aligns with green manufacturing practices by supporting the use of recyclable materials and facilitating the remanufacturing of worn components, extending the lifecycle of products and reducing industrial waste.</p><p><br></p><p>#injectionmolding #cncmachining #prototyping #sustainability</p>

APSX machines represent a significant breakthrough in modern agile manufacturing, designed to boost efficiency with easy setups, precision for injection molding over 3D printing, and scalability across diverse industrial sectors due to their low initial investment and small sizes. 

Top Benefits of Leveraging APSX Machines for Industrial Optimization

<p id="isPasted">Sensors and actuators are essential elements of industrial systems, instrumental to any application that requires automated control. Sensors measure changes in the environment while actuators control physical changes, with both devices serving as mediator between the physical environment and the electronic system where they are embedded.</p><p>Raspberry Pi provides general purpose header pins that can be connected to sensors, making the innovative low-cost board a popular and valuable choice for engineering prototypes. However, Pi’s GPIO pins are designed for driving low current devices such as LEDs, so is it possible to connect to the I/O necessary for industrial environments?</p><p>The type of sensors you’ll need to connect to your Pi will depend on the particular job your prototype is designed to perform. In manufacturing, the most common processes are concerned with monitoring and control:</p><ul><li>Temperature: Both contact and contactless sensors can be used to measure temperature.</li><li>Photoelectric: Ideal for counting specific objects using light or lasers.</li><li>Button and Switches: Simple human inputs used to control the functioning of a system.</li><li>Dial: Simple human input providing analogue/continuous control of a signal over a range of values.</li><li>Pressure: Useful for detecting blockages, and signalling when a system needs servicing.</li><li>Vibration: Often the first sign of a problem, sensors that detect changes in vibration are great for predictive maintenance.</li><li>RFID: Used to track and/or locate devices, personnel, and/or equipment.</li><li>Inductive: The typical automation sensor, alerting to the presence of metal.</li><li>Power Consumption: Key to understanding energy usage, also a useful signal for predictive maintenance</li></ul><p>Industrial sensors typically require 12-24V power and signal changes using the same voltage. Raspberry Pi’s GPIO input circuitry can be driven to either 3.3V (high) or 0V (low). This means that whilst a 12V water flow sensor might initially work hooked straight up to a Raspberry Pi, in long- term industrial projects the incompatibility of the currents will almost certainly cause problems.</p><h2>Does this mean Raspberry Pi can’t be connected to industrial sensors beyond a prototype?</h2><p>Connecting a sensor to Raspberry Pi directly often means stripping the sensors wiring and soldering the cable to the correct GPIO pin. The 12 or 24V of an industrial sensor will then be driven straight to the Pi with nothing in the way to protect Pi internal circuitry, including the processor. By adding extra circuitry as a buffer between the input pin and the Pi, it’s possible to extend the processor’s source/ sink current capabilities, and prevent excessive power dissipation in the chip.</p><h2>Breadboards and the Factory Floor</h2><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzI3NjY2MTkzNzgzLXZpc2hudS1tb2hhbmFuLXZ0Zzh0QWRvV1ZRLXVuc3BsYXNoLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Photo by Vishnu Mohanan on Unsplash</span></span></span></p><p id="isPasted">Breadboards are solderless circuit boards that can house the most complex circuits, making them an invaluable option for prototyping. The impermanence afforded by the boards allows you to build and test multiple circuits without the need to constantly solder rewired connections. In this way, breadboards are great for testing new parts, integrated circuits and for troubleshooting.</p><p>Some circuits will require a considerable amount of space, another feature of breadboards that makes them useful tools in industrial prototyping is the ability to extend the surface size by connecting multiples together.</p><p>While breadboards can go a long way in adapting Raspberry Pi for industrial applications, certain considerations may be prohibitive to deploying such a prototype directly to a factory environment. The completed set-up is undeniably still a prototype; the connections, whilst providing industrial I/O options, are not optimised for the rigours of the factory floor.&nbsp;</p><h2>Industrialised Pi</h2><p>Powered by Raspberry Pi, Brainboxes BB-400 is a smart industrial controller that allows prototypes to be deployed straight into industrial environments.&nbsp;</p><p><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzI3NjY2NTk4MTgyLWJiLTQwMC1waTMtMTAyNHg2ODEuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib"></p><p>Rather than adding protection to the GPIO using a breadboard and external circuitry, the built in circuitry of the BB-400 allows 12V and 24V sensors to be directly connected to the IO lines without the need to add additional components to step down the voltages.</p><h2>Never Lose a Configuration with Removable Terminal Blocks</h2><p>Using a screwdriver to connect sensors’ wires/cables into the embedded terminal blocks means that the circuitry doesn’t require soldering to create strong and secure connections, allowing multiple reconfigurations. As the terminal blocks can be unplugged, it’s easy to take the module out without affecting any of the pre-wired terminals.</p><p>As a single misplaced component leg can cause the whole circuit to malfunction or even cease to function at all, another useful feature of the terminal blocks is their numbering. It’s a lot easier to decipher the correct connection when you eliminate the need to count down a row of tiny header pins!</p><p>The BB-400 has 8 onboard digital I/O and multiple connectivity options: RS232/422/485 Serial port,</p><p>Bluetooth, Wi-Fi and Dual Ethernet, making it usable straight out of the box without the need for any add-on units. Packaged in an industrial DIN rail enclosure, the BB-400 is the perfect solution for deploying a Raspberry Pi prototype straight onto the factory floor.</p><p><a href="https://offer.brainboxes.com/prototyping-on-a-pi" target="_blank" rel="noopener noreferrer">Download the Prototyping with Pi E-book here. </a></p>

The type of sensors you’ll need to connect to your Pi will depend on the particular job your prototype is designed to perform. In manufacturing, the most common processes are concerned with monitoring and control

Unlock Industrial Prototyping: Your Guide to Connecting Industrial Sensors to Raspberry Pi

<p dir="ltr" id="isPasted">From the days when ICE cars saw minor updates every three years and major redesigns every five, we’ve shifted to an era where new EV models are released annually. The rapid evolution of electric vehicles is not only energizing the market, but also intensifying competition among manufacturers.</p><p dir="ltr">EV manufacturers need to innovate more quickly than ever to stay competitive in a market that’s expected to grow rapidly. According to<a href="https://www.grandviewresearch.com/industry-analysis/electric-powertrain-market" target="_blank">&nbsp;Grand View Research</a>, the global electric powertrain market was valued at $83.30 billion in 2022 and is projected to grow at a compound annual growth rate (CAGR) of 15.3% through 2030.</p><h2 dir="ltr">Manufacturing Challenges in EV Motors, Batteries, and ECUs</h2><p dir="ltr">At the heart of this rapid shift towards electric vehicles are three critical components: EV motors, batteries, and ECUs (Electronic Control Units). These elements form the backbone of every electric vehicle, powering its movement, optimizing energy efficiency, and managing complex operations. However, as the industry grows, so do the manufacturing challenges associated with these components.</p><h3 dir="ltr">EV Motors</h3><p dir="ltr">The design of EV motors is crucial for efficiency. Manufacturers now use thinner stamped lamination sheets (between 0.15 mm and 0.3 mm) to reduce power consumption, but producing these sheets requires extreme precision, especially when handling intricate profiles and sharp corners. Additionally, the need for lightweight materials and complex cooling systems to prevent overheating further complicates motor manufacturing. For mold makers, these factors demand high accuracy to ensure performance and keep assembly costs low.</p><h3 dir="ltr">Batteries</h3><p dir="ltr">Batteries serve as the heart of every EV, where power storage and management are critical to vehicle performance. Several production challenges arise:</p><ul><li dir="ltr">Efficient cooling systems are needed to prevent overheating during use.</li><li dir="ltr">Precise use of materials such as silicon carbide and ceramics is required for durability and heat resistance.</li><li dir="ltr">Perfectly sealed shields are essential to prevent leaks and sediments, which can compromise battery efficiency and safety.</li><li dir="ltr">The growing demand for smaller, lighter battery designs calls for highly accurate mold tooling and efficient production methods.</li></ul><h3 dir="ltr">ECUs (Electronic Control Units)</h3><p dir="ltr">These units manage critical functions such as power distribution and motor control. Producing intricate micro molds for ECUs is a significant challenge, as even small deviations can affect performance and safety. Manufacturers must ensure precision and consistency, particularly in customized production.</p><h2 dir="ltr">How Rapid Prototyping Solves These Manufacturing Challenges?</h2><p dir="ltr">Automotive Manufacturers need solutions that increase efficiency, reduce costs, and allow for greater customization. Rapid prototyping has become a key tool to address these challenges.</p><ul><li dir="ltr" style="font-weight: bold;"><strong>Digital Manufacturing and Quality Control</strong></li></ul><p dir="ltr">Rapid prototyping uses advanced digital manufacturing techniques to ensure precise production of complex components like thinner stamped lamination sheets for EV motors. By leveraging 3D printing and CNC machining, manufacturers can quickly create and test motor designs, optimizing for both efficiency and durability. This process allows for rapid iteration of complex cooling systems to prevent overheating, ensuring that all parts meet the required specifications.</p><ul><li dir="ltr" style="font-weight: bold;"><strong>Low-Volume, High-Customization Production</strong></li></ul><p dir="ltr">Battery production often requires customized solutions for challenges like efficient cooling and ensuring perfect seals. Rapid prototyping enables manufacturers to produce small batches of custom battery modules or cooling components at a lower cost. This flexibility allows for frequent design adjustments to meet the evolving demands for smaller, lighter batteries without costly retooling or manual interventions. It also ensures that material precision and sealing are tested and verified before large-scale production.</p><ul><li dir="ltr" style="font-weight: bold;"><strong>Supplier Integration for Streamlined Production</strong></li></ul><p dir="ltr">For EV manufacturers, working with a single supplier from prototype to full-scale production simplifies the process. Rapid prototyping allows seamless supplier integration, reducing the time and costs associated with switching suppliers. This ensures consistent quality and faster production, especially when developing critical components like motor housings and battery enclosures.</p><ul><li dir="ltr" style="font-weight: bold;"><strong>&nbsp;Accelerated Time-to-Market</strong></li></ul><p dir="ltr">In ECU development, where micro molds with extreme precision are essential, rapid prototyping accelerates the time-to-market by allowing manufacturers to quickly design, test, and refine intricate components like ECU casings and micro connectors. This ability to rapidly iterate and test designs ensures that production can proceed without long delays, meeting the stringent requirements for safety and performance in the fast-evolving EV market.</p><h2 dir="ltr">RPWORLD’s On-demand Manufacturing Solutions for EV Component Innovation</h2><p dir="ltr">RPWORLD offers a wide range of manufacturing services, including CNC machining, injection molding, vacuum casting, and a variety of finishing options, providing automotive customers the flexibility to select the best methods for developing and producing components. Whether for traditional ICE vehicles or EVs, our services enable rapid prototyping with the highest precision and shortest lead times. Our expertise in electric vehicle component development is extensive, offering specialized solutions for motors, batteries, and ECUs, such as:</p><ul><li dir="ltr">Precision motor housings and lamination components for optimal efficiency</li><li dir="ltr">High-quality battery pack enclosures and cooling system components</li><li dir="ltr">Custom-designed battery module connectors and management system housings</li><li dir="ltr">Detailed ECU casings and intricate micro connectors for zonal control units</li><li dir="ltr">Thermal management parts for both battery and ECU systems to ensure efficient heat dissipation</li></ul><p>As the automotive industry continues to shift toward electric vehicles, RPWORLD is proud to serve as a trusted partner, providing rapid prototyping solutions that help drive innovation and accelerate the transition to an all-electric future.<a href="https://www.rpworld.com/en/about-us/contact-us/" target="_blank">&nbsp;Let’s work together</a> to bring your EV projects to life.</p>

From the days when ICE cars saw minor updates every three years and major redesigns every five, we’ve shifted to an era where new EV models are released annually. The rapid evolution of electric vehicles is not only energizing the market, but also intensifying competition among manufacturers.

4 Ways Rapid Prototyping Accelerates Innovation in New Energy Vehicles

<p id="isPasted"><strong>Every day, millions of glass bottles, cans and PET containers run through a Krones line. <a href="https://www.krones.com/en/index.php" target="_blank">Krones</a> is a leading manufacturer of complete systems for breweries, beverage bottlers and food producers. Its production lines fill packages, add labels, and perform quality control on the products. As a global market player in the beverage and packaging industry, Krones provides comprehensive solutions that customers, such as Coca-Cola and Heineken, rely on heavily.</strong></p><p><strong><span contenteditable="false" draggable="true" class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable"><iframe width="640" height="360" src="https://www.youtube.com/embed/fdjkrFzIk84?&amp;wmode=opaque&amp;rel=0&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe></span></strong><br></p><h2>When every second counts</h2><p>The production lines of Krones are extremely efficient in producing, filling, and packing products. But with these massive production volumes, every second counts. When a machine is not running, companies could lose out on significant revenue. This is why it’s critical to have the highest possible uptime. While Krones machines are extremely reliable, every part will wear and might need replacing for optimal performance. While most customers keep a selection of spare parts, it’s unrealistic, expensive and unsustainable to keep a large stock of spares as many of these parts will never be used. Every part needs to be produced, checked and shipped.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzI2MDQxNjM5ODg2LUtyb25lcy11c2VyLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Every part produced for a Krones machine is checked for the highest quality.</span></span></span></p><h2 id="isPasted">3D printing at Krones</h2><p>To help customers get even more uptime, develop parts faster or create emergency spare parts, Krones turned to 3D printing. Outsourcing the production of prototypes is very expensive and often could take weeks. With the use of UltiMaker 3D printers, prototypes were able to be produced in a day, or even in hours in some cases. By prototyping faster, Krones tested and iterated on their designs faster, ensuring that new parts performed better and lasted longer. This has helped customers with more reliable machines, higher uptime and a smaller environmental footprint.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzI2MDQxNjY3MDU3LUtyb25lcy1hcHBsaWNhdGlvbi02LmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">3D printing in-house has enabled Krones to produce critical parts for their machines.</span></span></span></p><h2 id="isPasted">Benefits of 3D-printed parts over traditional parts</h2><p>By testing prototypes of parts, Krones discovered that 3D-printed parts met the performance requirements of many final parts. Not only are 3D-printed parts cheaper to produce, their reduced weight is also often a big benefit. Parts can also be printed in different materials depending on the need for different properties, such as more flexibility or ESD-safety. This enabled Krones to shift 3D printing from simply an internal tool to a new revenue stream as an added service for customers.</p><h2 id="isPasted">On-demand production parts for customers, anywhere</h2><p>When storing a huge stock of spare parts is not desirable or spare parts are needed urgently, you need to be able to acquire parts fast once they are needed. Ordering and shipping parts can take days to weeks, while local stocks or customs can make certain locations difficult to guarantee certain quality service. 3D printing on location offered a huge opportunity for Krones and its customers.</p><p>When customers need a spare part for a machine, they can order the part in the Krones.shop - the online customer touchpoint. If the spare part is able to be 3D-printed, it will be produced locally on UltiMaker printers. This way, customers won’t need to store huge quantities of spare parts in all of their locations. They can simply print the parts they need, while minimizing downtime of their production lines drastically. This process reduces part delivery from weeks to days, or even hours.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzI2MDQxNzAxMjU3LUtyb25lcy1hcHBsaWNhdGlvbi0xLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Printing parts on-demand have shown to reduce costs and improve operational efficiency.</span></span></span></p><h2 id="isPasted">Quality assurance of 3D printed parts</h2><p>The functionality and durability of a part depends on many factors. While the design of a part might be the same, the choice of materials and production settings have a great influence on the performance. Krones defines the right materials and print settings for every part. When a customer orders a replacement part for their Krones line, the spare will be 3D printed using customized settings and Krones-specific materials. This results in a certified part that is sure to meet the quality standards required. Krones quality can only be found where it says Krones Quality on the label.</p><h2>A flexible 3D printing solution that meets strict quality and IT standards</h2><p>Choosing the right 3D printing ecosystem can be very challenging. For Krones, UltiMaker was the right choice thanks to its agile, open and secure solutions. UltiMaker 3D printers have been known for their reliable and consistent quality. UltiMaker’s software comes with print profiles for hundreds of materials and brands, making it easy to pick the right material for the job. However, Krones was in need of a custom material with extremely specific requirements. Thanks to UltiMaker’s open materials platform, Krones was able to develop its own material for its own parts and create reliable print profiles.</p><p>UltiMaker’s professional software also helped Krones to meet the data protection standards set by IT. Print jobs on location are securely monitored by Krones through a custom software solution, assuring customers of the quality of the print job. Regular software and firmware updates also ensure Krones utilizes a future-proof 3D printing ecosystem.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzI2MDQxNzI4OTM2LUtyb25lcy1hcHBsaWNhdGlvbi00LmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">UltiMaker's 3D printing ecosystem and open materials platform allowed Krones to customize their solutions to meet customer demands.</span></span></span></p><h2 id="isPasted">Moving forward with the Factor 4</h2><p>Krones has been printing in over 10 locations using a large fleet of nearly 50 UltiMaker S5 and UltiMaker S7 printers. Adding the recently launched UltiMaker Factor 4 to its repertoire has brought new possibilities to Krones.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzI2MDQxNzUzMDYyLUtyb25lcy1GYWN0b3ItNC0xLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">The addition of UltiMaker's new Factor 4 3D printer has enabled Krones to provide more support to its customers.</span></span></span></p><p id="isPasted">Johannes Karl, Head of Customer 3D Solutions, at Krones, stated:</p><blockquote><p>We’re excited about the potential of the Factor 4. The Factor 4 has taken our capabilities to the next level. With support for stronger and more durable materials, we're able to produce parts that are not only tougher but also offer greater flexibility with softer materials.</p></blockquote><p>The new UltiMaker Factor 4 has a direct drive printhead. This makes printing soft materials easier and even more reliable. Because of the direct drive, the Factor 4 enables users to print parts in even softer and grippier materials. These features bring new opportunities for example for grippers, flexible parts or protective parts.</p><p>The new UltiMaker Factor 4 can also print at even higher temperatures, in a better isolated build chamber. This enables engineers to use materials such as UltiMaker’s PPS CF. A material that can easily substitute for PEEK or even steel.</p><p>The new features of the Factor 4 push innovation at Krones even further, helping them to deliver even more service to their customers.</p><p>Bernd Baldauf, Head of Global eBusiness - Global Digital Content Management - Global 3D Customer Solutions, at Krones, concluded:</p><blockquote><p>Our goal is to grow closer to our customers and become their solution partner. Providing rapid, high-quality parts on demand, and continuously improving our service offerings in Krones quality. With UltiMaker's innovative solutions, we're well on our way to achieving that.</p></blockquote>

Printing parts on-demand have shown to reduce costs and improve operational efficiency.

To help customers get even more uptime, develop parts faster or create emergency spare parts, Krones turned to 3D printing. With the use of UltiMaker 3D printers, prototypes were able to be produced in a day, or even in hours in some cases.

Krones: Optimized 3D-printed parts & spares for customers anywhere

<h3 dir="ltr">The Importance of Prototyping in PCB Development</h3><p dir="ltr">Prototyping is a crucial step to test and validate design before mass production. In the context of PCBs, prototyping helps identify issues in the board layout such as incorrect trace connections, and checks if the design can carry out its primary functions.</p><h3 dir="ltr">The Challenges of Traditional PCB Prototyping</h3><p dir="ltr">For years, traditional PCB prototyping methods played a key role in electronics development. However, these methods come with its fair share of challenges that hinder efficiency, cost-effectiveness, and speed.<br><br>For many small and mid-size businesses, especially startups, setting up traditional PCB prototyping equipment can be prohibitively expensive. Outsourcing to third-party manufacturers is another option, but it comes with its own set of challenges. Coordinating with external suppliers can result in long lead times and additional costs considering each design iteration requires programming their machines with your updated design files. On top of that, suppliers usually impose minimum order quantities, which means you could end up paying for more boards than you need.</p><h3 dir="ltr">A New Approach to Rapid PCB Prototyping</h3><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzI1OTgwMTk3NTc3LWxhcmdlVm9uZS5qcGVnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Image: Voltera V-One desktop PCB printer (Source:&nbsp;<a href="https://www.voltera.io/v-one?utm_campaign=Wevolver&utm_source=Blog&utm_content=V-One" target="_blank" rel="noopener noreferrer">Voltera</a>)</span></span></span>In today’s competitive market, getting your product to market quickly is crucial. That’s why rapid prototyping techniques are needed to stay ahead of the competition. The <a href="https://www.voltera.io/v-one?utm_campaign=Wevolver&utm_source=Blog&utm_content=V-One" target="_blank">Voltera V-One</a> desktop PCB printer is a game-changer in this space. It’s compact, cost-effective, and speeds up your product development process. In this article, we’ll dive into the V-One’s features and show you how to make the most of its capabilities so you can hit the ground running with this innovative tool.</p><h1 dir="ltr">What is the Voltera V-One?</h1><p dir="ltr">If you’re not familiar with PCB printers, picture them as similar to 3D printers, but instead of creating physical objects, they print intricate circuit patterns onto boards. Just as a 3D printer builds up layers of material to create a three-dimensional object, a PCB printer lays down conductive ink or other materials layer by layer to form the electrical pathways on a circuit board.</p><h3 dir="ltr">Why Choose the V-One for Prototyping?</h3><p dir="ltr">The V-One offers massive advantages over traditional prototyping processes by integrating PCB printing, drilling, and solder paste dispensing into a single system. This combination cuts iteration time from days and weeks to mere hours, allowing you to identify design errors early and reduce time to market.</p><p dir="ltr">The device supports an aligned printing feature, which comes in handy for printing on substrates with pre-existing features. This means you can print on popular development boards like Arduino and Raspberry Pi to create useful add-ons. It’s also perfect for creating double-sided PCBs without any hassle.</p><p dir="ltr">The V-One is a plug-and-play machine with user-friendly software. It is powerful enough to be trusted by experts at NASA, yet straightforward enough for a student to quickly learn. Whether you’re a seasoned engineer or just starting out, the V-One is designed for all skill levels.</p><p dir="ltr">Prototyping your PCBs in-house has the added perk of keeping your intellectual property safe. When you outsource PCB prototyping, there’s a chance of exposing your designs to unauthorized use, especially if you’re working with suppliers in areas where IP protection isn’t as strong.</p><h1 dir="ltr" id="isPasted">Double-Sided PCB Prototyping with the Voltera V-One</h1><p dir="ltr">In this tutorial, we’ll walk through the process of creating a double-sided PCB using the Voltera V-One, using a punk console as our example.</p><p dir="ltr"><strong>Step 1: Prepare and Upload Your Gerber File</strong></p><p dir="ltr">You can design your PCB layout using a variety of computer-aided design (CAD) software. The next step is to export your designs in Gerber files. Depending on your software of choice, Voltera offers a detailed Gerber export guide for KiCad, OrCAD, EAGLE, and Altium. Open the V-One software and upload your Gerber file. The software will automatically calculate the tool paths required for your design.</p><p dir="ltr"><strong>Step 2: Set Up the Printing Surface</strong></p><p dir="ltr">Since we’ll be drilling to make a double-sided board, place a sacrificial layer underneath the PCB to protect the bed from any potential damage. Secure the board and sacrificial layer in place by clamping them down onto the printer's bed.</p><p dir="ltr"><strong>Step 3: Surface Mapping</strong></p><p dir="ltr">Attach the proximity probe to the V-One. The software will map the board in XYZ space, preparing it for accurate drilling and trace printing.</p><p dir="ltr"><strong>Step 4: Drilling</strong></p><p dir="ltr">Replace the proximity probe with the drill head. Begin by drilling small holes for vias. Next, drill larger holes for through-hole components. The software will prompt you to change the drill bit as needed.</p><p dir="ltr"><strong>Step 5: Print Traces on the Top Side</strong></p><p dir="ltr">After drilling, clean off any debris from the board’s surface to ensure smooth printing. Swap out the drill head for the dispenser, and allow it to calibrate. Start printing the conductive traces on the top layer. If you notice any mistakes, the V-One offers a selective printing option that allows you to fix specific areas.</p><p dir="ltr"><strong>Step 6: Curing the Top Side</strong></p><p dir="ltr">After printing, remove the sacrificial layer. Flip the board over and rest it on the baking ledges of the clamps. The curing process takes about 40 minutes. Let the board cool down afterward.</p><p dir="ltr"><strong>Step 7: Print Traces on the Bottom Side</strong></p><p dir="ltr">Once the top side has cured, flip the board over to prepare for the bottom side printing. Use the aligned print option in the software, utilizing drilled holes to ensure the top and bottom sides are perfectly aligned.</p><p dir="ltr">Begin printing the conductive traces on the bottom side. Cure it using the same procedure as explained in step 6.</p><p dir="ltr"><strong>Step 8: Add Rivets to Connect Sides</strong></p><p dir="ltr">After both sides are printed, use rivets to connect the top and bottom sides at the drilled holes, ensuring proper electrical connectivity between the sides.</p><p dir="ltr"><strong>Step 9: Dispense Solder Paste</strong></p><p dir="ltr">Clamp the board back onto the printer, snap in the proximity probe, and remap the board to ensure accuracy. Replace the probe with the dispenser, this time with a cartridge of solder paste installed, rather than conductive ink. Dispense solder paste onto the designated pads for precise application.</p><p dir="ltr"><strong>Step 10: Reflow and Solder Components</strong></p><p dir="ltr">Place your components on the board and use the heated bed to reflow all surface-mount components in a single step. For through-hole components, use a soldering gun and solder wire to manually solder them in place.</p><h2 dir="ltr">Case Study: Creating a Wearable Device for Robotic Hand Control</h2><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzI1OTgwMzI5NzY3LXZvbHRlcmFfYXJ0MS5qcGVnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Image: Printed Strain Gauges on TPU laminated on a Glove for Remote Hand Control (Source:&nbsp;<a href="https://www.voltera.io/application-whitepapers/printing-strain-gauges-tpu-laminated-glove-remote-hand-control" target="_blank" rel="noopener noreferrer">Voltera</a>)</span></span></span></p><p dir="ltr" id="isPasted">Read how Voltera’s V-One PCB printer and NOVA materials dispensing system enabled a second-year undergrad studying Mechatronics, Robotics, and Automation Engineering at the University of Waterloo to design and build a fully functional robotic hand that mimics the movements of an operator wearing a control glove – in just two months.&nbsp;</p><p dir="ltr"><a href="https://www.voltera.io/application-whitepapers/printing-strain-gauges-tpu-laminated-glove-remote-hand-control" target="_blank">Printing Strain Gauges on TPU laminated on a Glove for Remote Hand Control</a></p><h2 dir="ltr" id="isPasted">Industries and applications where the V-One has made a significant impact</h2><p dir="ltr">Voltera V-One has been making significant contributions across various industries, showcasing its impact on research and development projects.</p><h3 dir="ltr">Advancing Solar Technology</h3><p dir="ltr">Researchers at The University of Akron used the V-One PCB printer to prototype modular solar (photovoltaic) shingles. Their goal was to create a more efficient manufacturing process using 3D printing and automated circuitry. By leveraging the V-One, they aimed to reduce both the cost and time required compared to traditional manufacturing methods. This innovative approach has the potential to make solar technology more accessible.</p><h3 dir="ltr">Eco-Friendly Supercapacitors</h3><p dir="ltr">At Tampere University, researchers utilized the V-One alongside additive manufacturing techniques to develop a functional supercapacitor. What sets this project apart is its focus on sustainability. The entire process used only environmentally safe and biodegradable materials. This achievement demonstrates the V-One's ability to drive green technology initiatives.</p><h3 dir="ltr">Aerospace Innovations with CubeSats</h3><p dir="ltr">The aerospace industry has also benefited from the V-One's capabilities. At Princeton University, the V-One was instrumental in <a href="https://www.voltera.io/customer-stories/princeton-university?utm_campaign=Wevolver&utm_source=Wevolver&utm_content=Princeton%20Customer%20Story" target="_blank">building CubeSats</a>—small, cube-shaped satellites used for space research. These miniature satellites are essential for studying various aspects of space and planetary science. The V-One’s ability to quickly produce PCBs helped streamline the development process, enabling Princeton’s research students to focus on innovation and experimentation.</p><p dir="ltr">These partnerships not only showcase V-One's adaptability but also underscore its potential to accelerate research and development in advanced technological fields.</p><h1 dir="ltr" id="isPasted">Future-Proofing Your Prototyping Process</h1><h3 dir="ltr">How the V-One can be integrated into a larger prototyping workflow</h3><p dir="ltr">Incorporating the Voltera V-One PCB printer into a broader prototyping workflow can accelerate your product development process. By pairing the V-One with other prototyping tools like 3D printers, you can design and create PCBs along with enclosures or other mechanical parts in-house. This integrated approach not only saves time but also allows for rapid iteration and refinement of designs.</p><h1 dir="ltr">Conclusion</h1><p dir="ltr">The V-One speeds up the prototyping process significantly. With its ability to quickly print PCBs, drill vias, and dispense solder paste, you can iterate on designs in hours rather than days or weeks. By handling PCB prototyping in-house, the V-One cuts out costly third-party manufacturing and logistics expenses. It also helps protect your designs and intellectual property. Plus, its plug-and-play setup makes it easy to use and shortens the learning curve.</p><p>Curious to see how the V-One can fit into your workflow? Book a call with the team at Voltera to explore how this innovative tool can meet your prototyping needs.</p><p><a href="https://meetings.hubspot.com/royperez/v-one-or-nova-demo?utm_campaign=Wevolver&utm_source=Wevolver&utm_medium=Book%20a%20meeting" target="_blank" rel="noopener noreferrer" class="button-main-action">Get in touch with the team</a></p>

Everything You Need to Know About Prototyping with the Voltera V-One: A Focus on Double-Sided PCBs

A Complete Guide to Prototyping Double-Sided PCBs in One Day

<p dir="ltr" id="isPasted">The transportation industry is rapidly evolving, driven by a global shift towards electrification. Ambitious climate goals and growing consumer demand for sustainability have made the electric vehicle (EV) market a center of innovation.</p><p dir="ltr">In this evolving landscape, virtual prototyping has become vital for engineers, enabling more efficient and flexible EV development. While physical testing remains essential, its time and cost constraints can limit its effectiveness, making virtual prototyping indispensable for rapid, cost-effective design optimization.</p><p dir="ltr">Virtual prototyping leverages predictive, real-time, and immersive simulation software, allowing engineers across domains to design, test, and validate vehicle components and systems in a digital, single-source environment before building any physical prototypes. It accelerates development, reduces costs, and fosters innovation by enabling rapid iteration and collaborative decision-making, particularly in exploring new designs, battery technology, and lightweight materials.</p><p dir="ltr">Leading automakers such as Volvo, Toyota, SEAT, Renault, Toyoda Gosei, Hyundai, and Audi have embraced virtual prototyping in some capacity to stay competitive in this ever-evolving EV market and meet growing demands for sustainable, high-performance vehicles. This progressive approach enhances design efficiency and aligns with the industry's broader shift towards innovation.1</p><p dir="ltr"><a href="https://www.esi-group.com/company/who-we-are" target="_blank">ESI Group</a>, a pioneer in this field, has been at the forefront of virtual prototyping since its first-ever crash simulation with Volkswagen in 1985. Today, ESI leads the field by setting new standards for virtual homologation, enabling automakers to validate their designs from the outset and eliminating the need for multiple costly and time-consuming physical prototypes for safety certification.</p><p dir="ltr">This article provides an overview of how ESI's virtual prototyping solutions are transforming EV development.</p><h2 dir="ltr" id="isPasted">Overcoming Crash and Safety Testing Challenges</h2><p dir="ltr">Vehicle safety and structural integrity are critical in automotive design, especially for EVs. Simulation techniques are essential for analyzing crash dynamics, safety features, and overall performance. This approach allows designers to rapidly develop innovative solutions that meet evolving regulations and e-mobility challenges, ultimately leading to safer and more efficient vehicles.</p><p dir="ltr">Here is how ESI's <a href="https://www.esi-group.com/products/virtual-performance-solution" target="_blank">virtual performance simulation</a> (VPS) software helps engineers tackle the most challenging cases in automotive engineering:</p><ul><li dir="ltr"><p dir="ltr">Struggling with tight deadlines for testing crash scenarios?&nbsp;Test various scenarios in virtual crash simulation, including frontal, side pole, and far-side collisions, to evaluate vehicle deformation and its impact on occupants and pedestrians without the cost and delays of physical tests.2</p></li><li dir="ltr"><p dir="ltr">Need to analyze complex airbag deployment? VPS accurately models and simulates airbag folding and deployment, including intricate side curtain airbags and non-uniform pressures, and is renowned for its unmatched accuracy and efficiency.3&nbsp;</p></li><li dir="ltr"><p dir="ltr">Concerned about evaluating battery performance and safety early in development? Assess full car crash scenarios, regulatory crush analysis, and battery stiffness, shock, and swelling in crash and safety simulation to ensure designs meet rigorous safety standards before physical testing.4&nbsp;</p></li><li dir="ltr"><p dir="ltr">Looking for a cost-effective way to assess vehicle strength and dynamics?&nbsp;Use ESI's single simulation tool to evaluate vehicle strength and dynamics, including stiffness, pothole impacts, door and hood durability, and the impact of water crossing. This enhances reliability while reducing testing mileage and material cost, making it more environmentally friendly.&nbsp;5</p></li></ul><p dir="ltr">In short, ESI's simulation software for virtual crash, safety, and structural testing enables you to effectively manage the complexities of modern vehicle design.</p><p dir="ltr">However, another crucial aspect of vehicle performance engineering that demands just as much attention is vibro-acoustic performance.</p><h2 dir="ltr">Mastering Noise and Sound to Enhance EV Acoustics</h2><p dir="ltr">As vehicle electrification increases, managing acoustic comfort and compliance with noise regulations becomes increasingly crucial. Traditional acoustic testing may not address the complexities of new EVs, making virtual vibro-acoustic simulation a more comprehensive approach for optimizing interior and exterior noise.&nbsp;</p><p dir="ltr">But how efficiently can you conduct vibro-acoustic analysis? Are you struggling to ensure a quiet, comfortable environment for passengers while meeting pass-by noise regulations and ensuring effective acoustic warning systems?</p><p dir="ltr">Here's how ESI's <a href="https://www.esi-group.com/products/va-one" target="_blank">vibro-acoustic simulation software</a> can help you test and optimize interior and exterior noise performance, ensuring comfort, compliance and protection:</p><ul><li dir="ltr"><p dir="ltr">Airborne Noise Simulation: Optimizes how noise control treatments affect cabin acoustics.</p></li><li dir="ltr"><p dir="ltr">Structure-Borne Noise Analysis: Evaluates noise generated through structural loads.</p></li><li dir="ltr"><p dir="ltr">Sound Package Design and Optimization: Designs and tests noise control countermeasures to enhance acoustic performance.</p></li><li dir="ltr"><p dir="ltr">Pass-By Noise (PBN) Simulation: Ensures vehicles meet regulatory noise standards.</p></li><li dir="ltr"><p dir="ltr">Acoustic Vehicle Alerting Systems (AVAS): Designs effective warning sounds to enhance safety.</p></li><li dir="ltr"><p dir="ltr">Wind Noise: Predicts the effect of wind noise on acoustic comfort by integrating CFD data into the vehicle models.</p></li><li dir="ltr"><p dir="ltr">Auralization: Creates realistic sound scenarios to evaluate the acoustic environment before physical testing.</p></li></ul><ul id="isPasted"><li dir="ltr"><p dir="ltr">Road Noise Simulation: Predicts and optimizes noise levels from road interactions.6,7</p></li></ul><p><br></p><p dir="ltr" id="isPasted">With safety and acoustic performance validated, the next step is manufacturability. Just as simulation software has transformed performance testing, manufacturing simulation enhances and optimizes production processes and part performance, ensuring the designs are realized with precision and efficiency.</p><h2 dir="ltr">Virtual Manufacturing for Lightweight Materials and Processes</h2><p dir="ltr">Lightweight materials are essential in modern vehicle body and chassis design as automakers seek to reduce weight for improved fuel efficiency and performance. This shift has led to a transition from only steel to multi-material strategies that combine steel with aluminum and composites such as carbon fiber.</p><p dir="ltr">While these approaches reduce vehicle weight and maintain excellent crash performance, they also introduce new manufacturing challenges, necessitating the validation of the optimal combination of lightweight materials and joining processes to achieve the best performance-cost-weight ratio.</p><p dir="ltr">To address these challenges, automakers should frontload their manufacturing decisions by creating a virtual manufacturing process chain. This approach provides early confidence in material selection, manufacturing methods, and assembly processes before physical production, reducing the risk of costly revisions and ensuring a smoother transition from design to manufacturing.&nbsp;</p><p dir="ltr">ESI's <a href="https://www.esi-group.com/industries/automotive/body-chassis-manufacturing" target="_blank">multi-material assembly simulation</a> allows for thorough evaluation and optimization using the following virtual manufacturing simulation tools:</p><ul><li dir="ltr"><p dir="ltr">ProCAST:&nbsp;Predicts and eliminates defects, such as misruns, inclusions, shrinkage porosity, cracks, and excessive distortions, in various casting processes, including large-scale or mega castings.8</p></li><li dir="ltr"><p dir="ltr">PAM-STAMP:&nbsp;Virtually assesses defect formation, predicts and compensates for spring back in high-strength steels and aluminum, and explores advanced processes like press hardening.9</p></li><li dir="ltr"><p dir="ltr">SYSWELD:&nbsp;Ensures robust, durable spot welds by predicting weld strength and quality. Analyze each assembly step, minimize distortions from gap closing and joining processes, and optimize weld sequences to control final assembly distortions.&nbsp;10</p></li><li dir="ltr"><p dir="ltr">PAM-COMPOSITES:&nbsp;The only complete simulation chain that identifies and fixes manufacturing defects in composite products, covering draping, thermoforming, various resin molding processes, infusion, curing, and geometrical distortions.11</p></li></ul><p dir="ltr">However, developing sustainable, safe, and comfortable vehicles is just one part of the equation; integrating the human aspect from the early design stages is crucial for perfecting a new vehicle.</p><p dir="ltr">This is where advanced immersive virtual reality (VR) software comes into play.</p><p dir="ltr"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzI1ODg2NjA2Mzk0LUVTSV9MSVZFX0FVVE9fV2V2b2x2ZXJfMDJfODAweDUwMF92MDEuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib"></p><p><br></p><h2 dir="ltr" id="isPasted">The Industrial Metaverse for Virtual Build and Immersive Product Integration</h2><p dir="ltr">Innovating in EV design and manufacturing introduces new risks that may not be apparent until production begins. These include components integration, assembly, installation or removal challenges, and maintenance issues.</p><p dir="ltr">Without physical prototypes for early evaluation, these issues can lead to production bottlenecks and missed opportunities for optimization, impacting EV's overall success.</p><p dir="ltr">ESI's <a href="https://www.esi-group.com/products/ic-ido" target="_blank">IC.IDO</a> (virtual reality software) offers an innovative solution, allowing automakers to experience their products within a collaborative industrial metaverse. It provides physically realistic virtual experiences for product assembly and maintenance, offering opportunities to:</p><ul><li dir="ltr"><p dir="ltr">Evaluate&nbsp;space constraints, clearances, visibility, and component accessibility.</p></li><li dir="ltr"><p dir="ltr">Assess and optimize&nbsp;cable and hose routing and handling.</p></li><li dir="ltr"><p dir="ltr">Define and refine&nbsp;installation and removal paths.</p></li><li dir="ltr"><p dir="ltr">Develop,&nbsp;test, playback, refine, and optimize assembly processes.</p></li><li dir="ltr"><p dir="ltr">Validate&nbsp;procedures, work cells, and production lines.</p></li></ul><p dir="ltr">Identifying potential issues early with VR accelerates the development process, reduces costs, and improves the quality and safety of the final product. Therefore, automakers can optimize the entire product lifecycle from initial concept to final assembly by simulating real-world interactions with virtual prototypes.&nbsp;</p><h2 dir="ltr">Discover More EV Innovation at ESI LIVE Automotive</h2><p dir="ltr">To explore these fundamental simulation technologies in detail and gain valuable insights from leading experts, attend ESI LIVE Automotive. This event offers a comprehensive overview of predictive modeling and virtual prototyping through practical examples from the automotive industry.</p><p dir="ltr">Attendees will learn about optimizing EV safety and comfort, mastering noise and sound, virtual manufacturing for lightweight materials, and the role of the industrial metaverse in virtual build and product integration.</p><p dir="ltr">Discover how these technologies are advancing electric vehicle design. Join us to gain valuable insights from industry experts and stay up-to-date with the latest developments.</p><p dir="ltr"><strong>What:</strong>&nbsp;ESI Live automotive digital event</p><p dir="ltr"><strong>When:</strong>&nbsp;October 24th, 2-4 PM CET</p><p dir="ltr"><strong>Register:</strong> Free to attend.&nbsp;</p><p dir="ltr"><a href="https://esiliveautomotive.vfairs.com/en/registration?utm_source=wevolver&utm_medium=all&utm_campaign=registration" target="_blank" rel="noopener noreferrer" class="button-main-action">Sign up to attend here.</a></p><p dir="ltr">&nbsp;</p><p dir="ltr">For more information and to register, visit <a href="https://www.wevolver.com/article/esi-live-automotive-digital-event-empowering-innovation-through-virtual-prototyping/draft" target="_blank" rel="noopener noreferrer">ESI LIVE Automotive</a>.</p><h3 dir="ltr">References</h3><ol><li dir="ltr"><p dir="ltr">ESI Group. How is Virtual Prototyping Accelerating Electric Vehicle Development? [Online]. Available at: <a href="https://www.esi-group.com/ebook-how-is-virtual-prototyping-accelerating-electric-vehicle-development" target="_blank">https://www.esi-group.com/ebook-how-is-virtual-prototyping-accelerating-electric-vehicle-development</a>&nbsp;</p></li><li dir="ltr"><p dir="ltr">ESI Group. Virtual Performance Solution - Software to Simulate &amp; Test Crash &amp; Safety. [Online]. Available at: <a href="https://www.esi-group.com/products/virtual-performance-solution/crash-and-safety" target="_blank">https://www.esi-group.com/products/virtual-performance-solution/crash-and-safety</a>&nbsp;</p></li><li dir="ltr"><p dir="ltr">Baccari, N. Toyoda Gosei Europe Cuts Lead Times in Half Using Virtual Prototyping. (2020). [Online]. Available at: <a href="https://www.esi-group.com/blog/toyoda-gosei-europe-cuts-lead-times-in-half-using-virtual-prototyping" target="_blank">https://www.esi-group.com/blog/toyoda-gosei-europe-cuts-lead-times-in-half-using-virtual-prototyping</a></p></li><li dir="ltr"><p dir="ltr">ESI Group. Software to Simulate Battery Safety. [Online]. Available at: <a href="https://www.esi-group.com/products/virtual-performance-solution/battery-safety" target="_blank">https://www.esi-group.com/products/virtual-performance-solution/battery-safety</a></p></li><li dir="ltr"><p dir="ltr">ESI Group. Software to Simulate Strength &amp; Dynamics. [Online]. Available at: <a href="https://www.esi-group.com/products/virtual-performance-solution/strength-and-dynamics" target="_blank">https://www.esi-group.com/products/virtual-performance-solution/strength-and-dynamics</a></p></li><li dir="ltr"><p dir="ltr">ESI Group. Simulation Software Solutions for Acoustic Performance. [Online]. Available at: <a href="https://www.esi-group.com/industries/automotive/simulation-software-solutions-for-acoustic-performance" target="_blank">https://www.esi-group.com/industries/automotive/simulation-software-solutions-for-acoustic-performance</a></p></li><li dir="ltr"><p dir="ltr">ESI Group. VA One - Interior Acoustics Simulation Software. [Online]. Available at: <a href="https://www.esi-group.com/products/va-one/interior-acoustics-simulation-software" target="_blank">https://www.esi-group.com/products/va-one/interior-acoustics-simulation-software</a></p></li><li dir="ltr"><p dir="ltr">ESI Group. ProCAST - Casting Simulation Software. [Online]. Available at: <a href="https://www.esi-group.com/products/procast" target="_blank">https://www.esi-group.com/products/procast</a></p></li><li dir="ltr"><p dir="ltr">ESI Group. PAM-COMPOSITES - Composite Simulation Software. [Online]. Available at: <a href="https://www.esi-group.com/products/pam-composites" target="_blank">https://www.esi-group.com/products/pam-composites</a></p></li><li dir="ltr"><p dir="ltr">ESI Group. SYSWELD - Welding &amp; Assembly Simulation Software. [Online]. Available at: <a href="https://www.esi-group.com/products/sysweld" target="_blank">https://www.esi-group.com/products/sysweld</a></p></li><li dir="ltr"><p dir="ltr">ESI Group. PAM-STAMP - Stamping Simulation Software. [Online]. Available at: <a href="https://www.esi-group.com/products/pam-stamp" target="_blank">https://www.esi-group.com/products/pam-stamp</a>&nbsp;</p></li></ol><p>ESI Group. IC.IDO - Virtual Reality Engineering Software. [Online]. Available at: <a href="https://www.esi-group.com/products/ic-ido" target="_blank">https://www.esi-group.com/products/ic-ido</a>&nbsp;</p>

Virtual prototyping is essential for efficient, flexible EV development, complementing physical testing to overcome time and cost constraints.

How to Drive Faster and More Collaborative Decision-Making for Next-Generation Vehicle Development

<p id="isPasted"><a href="https://esiliveautomotive.vfairs.com/" target="_blank" rel="noopener noreferrer">ESI LIVE Automotive</a> is an event that’s dedicated to driving EV innovation through the power of virtual prototyping. Attend online on October 24<sup>th</sup> to discover how ESI’s cutting-edge simulation software supercharges design cycles, boosts efficiency, and ensures flawless manufacturability.</p><p>Get ready to explore game-changing strategies for optimizing EV safety, comfort, and durability with the latest digital innovations. Dive into mastering EV acoustics, and see how virtual manufacturing is driving the shift towards lightweight materials. Take a step into the industrial metaverse where XR technology is redefining collaboration in design, manufacturing, and maintenance.&nbsp;</p><p>Sign up for ESI LIVE Automotive and attend insightful panel discussions, hear inspiring customer stories, and grab a front-row seat to the future of the EV industry!</p><table style="width: 98%; margin-right: calc(2%);"><tbody><tr><td style="width: 100%;"><strong>What:&nbsp;</strong>ESI LIVE Automotive digital event<br><strong>When:</strong> October 24th, 2-4 PM CET<br><strong>Register:</strong> Free to attend.&nbsp;<a href="https://esiliveautomotive.vfairs.com/en/registration?utm_source=wevolver&utm_medium=all&utm_campaign=registration" target="_blank" rel="noopener noreferrer">Sign up to attend here.</a><br></td></tr></tbody></table><h3 id="isPasted"><strong>Highlights of ESI LIVE:</strong><br>&nbsp;</h3><ul><li><strong>Optimizing EV safety, comfort, and durability:&nbsp;</strong><br>&nbsp;Discover innovative strategies for ensuring safety compliance, enhancing seating design and pre-certification, and streamlining the design process of complex systems through cutting-edge digital solutions.</li><li><strong>Mastering noise and sound-enhancing EV acoustics:&nbsp;<br>&nbsp;</strong>Identify next-generation simulation methodologies and innovative design techniques come together to revolutionize acoustic performance in electric vehicles.</li><li><strong>Virtual manufacturing for lightweight materials and processes:<br>&nbsp;</strong>Learn how to find the most efficient materials and manufacturing processes to achieve assemblies with optimal cost/quality ratio, ensuring correct performance.</li><li><strong>Industrial metaverse for virtual build &amp; immersive product integration:<br>&nbsp;</strong>Explore how XR technology breaks silos, fostering collaboration between design, manufacturing, and maintenance teams.</li></ul><p>Take advantage of this opportunity to hear customer stories, engage in insightful panel discussions, and witness firsthand the transformative capabilities of Virtual Prototyping in shaping the future of EV industry solutions.&nbsp;</p><p><a href="https://esiliveautomotive.vfairs.com/en/#agenda" target="_blank" rel="noopener noreferrer" class="button-main-action">Check out the agenda below.</a></p><table border="1" cellspacing="0" cellpadding="0" width="600" id="isPasted"><tbody><tr><td width="100%" colspan="3" valign="top"><p><strong>ESI LIVE AUTOMOTIVE 2024 AGENDA</strong></p></td></tr><tr><td width="19%" valign="top"><p><strong>Date &amp; Time</strong></p></td><td width="30.833333333333332%" valign="top"><p><strong>Track theme</strong></p></td><td width="50.166666666666664%" valign="top"><p><strong>Details</strong></p></td></tr><tr><td width="19%" valign="top"><p>October 24, 02:00 pm CET</p></td><td width="30.833333333333332%" valign="top"><p>Optimizing EV safety, comfort, and durability.</p><p>&nbsp;</p></td><td width="50.166666666666664%" valign="top"><p>The sessions cover key topics in automotive design and compliance. The first session discusses maintaining safety regulations and optimizing vehicle design within virtual homologation. The second session focuses on the effective design, manufacturing, testing, and pre-certification of vehicle seating. The final session explores the use of a digital thread in the design process of complex systems.</p></td></tr><tr><td width="19%" valign="top"><p>October 24, 02:00 pm CET</p></td><td width="30.833333333333332%" valign="top"><p>Empowering EV innovation: virtual manufacturing for lightweight materials and processes.</p><p>&nbsp;</p></td><td width="50.166666666666664%" valign="top"><p>The sessions focus on advancements in electric mobility and lightweight materials. The first session addresses the use of manufacturing simulations to evaluate performance in mega-casting components for electric vehicles. The second session discusses the challenges of using lightweight aluminum for stamping Class A panels. The final session covers innovative, high-efficiency components designed for electric and hydrogen vehicles.</p></td></tr><tr><td width="19%" valign="top"><p>October 24, 02:00 pm CET</p></td><td width="30.833333333333332%" valign="top"><p>Industrial metaverse for virtual build &amp; immersive product integration.</p><p>&nbsp;</p></td><td width="50.166666666666664%" valign="top"><p>The sessions explore integrating advanced virtual and immersive technologies in mobility and product development. The first session discusses how extended reality is shaping the future of mobility today. The second session focuses on enterprise virtuality and collaborative virtual builds. The final session examines human-centric process validation and immersive product integration.</p></td></tr></tbody></table><h3><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzI1ODgzNDMxMDY1LXBkZi5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib"></h3><h3 id="isPasted"><strong>Why you should attend:&nbsp;</strong></h3><p>Attending ESI LIVE Automotive offers a unique experience for professionals in the automotive industry, particularly those focused on electric vehicle (EV) development. Participants will have the chance to engage with thought leaders, network with peers, and gain insights into the latest advancements in EV design, manufacturing, and sustainability.&nbsp;</p><p>By attending, you'll not only stay ahead of industry shifts but also contribute to the critical conversations that are driving the electric vehicle revolution. This event is more than just an opportunity to learn—it's a chance to collaborate on groundbreaking ideas that will define the next era of mobility. Your presence and participation will help push the boundaries of what's possible, empowering innovation and fostering a sustainable transportation future.</p><p>We look forward to seeing you there, as together, we can make a significant impact on the future of automotive technology and sustainable mobility.</p><h3><strong>More details</strong></h3><p>To attend the ESI Live Automotive event, <a href="https://esiliveautomotive.vfairs.com/en/registration?utm_source=wevolver&utm_medium=all&utm_campaign=registration" target="_blank" rel="noopener noreferrer">register here</a> - the event is free.&nbsp;</p><p><a href="https://esiliveautomotive.vfairs.com/en/registration?utm_source=wevolver&utm_medium=all&utm_campaign=registration" target="_blank" rel="noopener noreferrer" class="button-main-action">Register here.</a></p><p>The vFairs platform used for the event is accessible from any device or browser. If you have any questions, you can email event@esi-group.com.&nbsp;</p><p>We encourage you to share the registration link with others who may benefit from the event. Your registration information will be used to create your login credentials and follow up. For more details, you can check the <a href="https://www.esi-group.com/privacy-terms-of-use" target="_blank" rel="noopener noreferrer">terms and conditions.</a></p>

Register for the live event, October 24th, 2-4 PM CET


ESI LIVE automotive digital event: Empowering innovation through virtual prototyping

<h2 id="isPasted">New whitepaper: How Augmented Reality is redefining product development.</h2><p dir="ltr">Augmented Reality (AR) is not just a tool; it's a transformative force that is reshaping many processes in business. Production companies, in particular, benefit from AR because they can leverage its benefits along their entire value chain, from product development to manufacturing, logistics, marketing, customer service, and employee training.&nbsp;</p><p dir="ltr">In the recent white paper from HoloLight, 'AR as a Booster for Industry 4.0,' you can explore the ways in which AR can have a significant transformative impact.&nbsp;</p><p dir="ltr"><strong>Key highlights of the whitepaper:</strong></p><ul><li dir="ltr">Learn how companies can use AR to increase the quality and productivity of their entire process chain</li><li dir="ltr">Understand what a consistent Augmented Reality strategy can look like and how to implement one.</li><li dir="ltr">Discover how well-known companies are already successfully using AR through detailed case studies.&nbsp;</li></ul><p dir="ltr">Don't miss out on these valuable insights. Get your copy of the white paper now by filling out the simple form below.&nbsp;</p><p><span contenteditable="false" draggable="true" class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable fr-active"><iframe id="JotFormIFrame-241713238748360" title="Hololight Form" allowtransparency="true" src="https://form.jotform.com/241713238748360" frameborder="0" style="min-width:100%;max-width:100%;height:539px;border:none;" scrolling="no" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"> </iframe></span></p><p dir="ltr" id="isPasted"><a href="https://hololight.com/lns-group-saves-prototyping-costs-for-machine-tools/" target="_blank" rel="noopener noreferrer">LNS Group</a>, a Swiss leader in machine tool peripherals, is driving immersive technologies throughout its product development cycles. From early design reviews with global stakeholders to risk assessment and handover to operations, the company is reducing time-to-market by 3 months and saving $5,000 to $10,000 per prototype while improving product quality.</p><p dir="ltr">LNS Group is a global Swiss machine tool peripherals specialist that operates four different product lines and has nine production sites across Switzerland, Italy, the UK, Taiwan, China, Japan, and the USA. The company has around 1,000 dedicated professionals worldwide and is known for its strong focus on research and development as well as its global presence. “The way we communicate is key to the success of the product,” emphasizes Jamie Towers, CTO of LNS. “You can’t really quantify it, but the most important thing in product development is to get buy-in from all the stakeholders and have everyone understand and agree on what we’re trying to accomplish as early as possible.”</p><p dir="ltr">Easier said than done. The CTO and the innovation team recognized the early need to integrate industrial augmented and virtual reality (AR/VR) into their research and development processes to encourage better communication and collaboration among global teams and departments. “We chose the XR Engineering solution, <a href="https://hololight.com/" target="_blank" rel="noopener noreferrer">Hololight Space</a>, because it met our vision for adaptability and ease of use right from the start. We upload our designs to the cloud platform and simply start a collaborative meeting. In our industry, complexity often leads to resistance, but the solution’s straightforward functionality means our team can focus on pushing the boundaries of innovation without the frustration of dealing with cumbersome systems.”</p><h2>How LNS Group Engages Non-Design Teams with Augmented Reality for Better Outcomes</h2><p>LNS specializes in manufacturing bar feeders, chip conveyors, air filtration, and coolant management systems, &nbsp;essential for the automotive, watch, medical, and aerospace industries. The company follows a standard product development process. They start by reviewing market requirements, then proceed to the development phase, and finally return to the market for implementation.. “We’re 100% committed to delivering customer-focused products,” says Towers. “The only way to do that is to really work with the customer and the people who face the customer. That’s your sales team, that’s your customer service team. And those are the hardest people to engage when it comes to design reviews,” he adds with a smile.</p><p>Non-design teams often struggle with the challenge of visualizing products from onscreen models alone. The difficulty of assessing scale, accessibility, and maintenance considerations from a 3D model on a 2D screen can create a gap in understanding the product in tangible terms, making it difficult to provide the concrete feedback engineers need to better tailor the product to customer needs. This gap often requires the creation and global distribution of multiple prototype versions, at significant financial and environmental cost. Hololight Space now provides a dynamic digital workspace for seamless interaction with 3D CAD data in both AR and VR environments. Users can visualize and work with their 3D content to review designs, plan a factory layout, perform quality assurance, or verify assembly processes. Data is streamed from powerful on-premises or cloud servers with Nvidia GRID GPUs to ensure high levels of security and high-quality visualization without the need for data optimization.</p><p><span contenteditable="false" draggable="true" class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable"><iframe width="640" height="360" src="https://www.youtube.com/embed/pX3jw1FnRyw?&amp;wmode=opaque&amp;rel=0&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe></span><br></p><h3>Use Case 1 – How LNS Group Uses AR for Worldwide Collaboration &amp; Design Reviews</h3><p>Using Hololight Space in the design process heralds a transformative shift. Teams can visualize products in real-world contexts, facilitating more accurate and comprehensive early-stage reviews. Tangible interaction with a product before it is physically created, leads to the development of more accurate initial prototypes, significantly shortening the iterative cycle of prototyping. “Visualizing our designs in AR and the real world helps us get valuable feedback from our sales and customer service teams on what might need to be tweaked to better meet customer needs. It also works very well with our customer service teams, such as checking the accessibility on the digital twin to see how we can service a particular product,” explains Brian Scruggs, Global Engineering Administrator at LNS. “We typically use Hololight Space to highlight key features that we need specific feedback on, and then everyone can look at the design together, we take notes, and we also use the live stream so everyone can follow along.”</p><p>Including AR in the design review process not only improves communication but also enhances buy-in from stakeholders. “We are able to get products from the drawing board to market in a short period of time – from large developments with many stakeholders to smaller projects with small groups,” notes Scruggs. By removing the barriers to visualization, AR reduces the number of prototypes needed, thereby lowering costs and minimizing environmental impact. In addition, effective design reviews cultivate company-wide support, reducing the frustration often associated with late-stage design changes. “The ease of use is a critical point, having the backup and support behind it is also a key, and frankly the price point is right for what we need. For us, using Hololight Space is now like turning on a computer. It is second nature to us,” concludes Scruggs.</p><h2>Use Case 2 – How LNS Group Masters CE Compliance and Risk Assessment Across Borders</h2><p>Leveraging its global R&amp;D network, LNS usually designs products in one region and manufactures them in another.. The company manages CE compliance from Switzerland with the help of external consultants. This is an important step in the product development process and is often performed, along with a risk assessment, near the end of the prototyping phase.. “Changes – and there are almost always changes – can have a profound impact on the design, cost and overall concept of the product. As a result, compliance assessments introduced later in the process can add significant time to the schedule,” states Jamie Towers, CTO of LNS. “We were looking for a way to do risk assessment earlier in the design process, before we even built a prototype, not only internally but also with our external consultants.”</p><p>Global Engineering Administrator Brian Scruggs elaborates, “To give an example, we had a project in China with a large machine tool manufacturer where the product would end up in Europe and instead of shipping a product to Switzerland, we decided to use Hololight Space to do a remote risk assessment with our external consultant. We did the risk assessment in Augmented Reality, discovered some changes that needed to be made, and were able to fix the mistakes before we ever built and shipped a product to Europe.” By avoiding shipping, travel, and building a prototype, LNS was able to save $5,000 to $10,000, while significantly reducing the environmental costs associated with building multiple prototype iterations. “We saved at least three months of project time by conducting early risk assessments and avoiding the need for later “patches” to the design,” reports Scruggs. “The result is not only a reduction in time and cost, but also a product that truly meets the practical considerations of the user.”</p><h2>Use Case 3 – How LNS Group Streamlines Operations Handover with Industrial Augmented Reality</h2><p>Finally, “handover to operations” is a pivotal moment. It’s the critical transition where all the plans, prototypes, and theoretical work are handed over to the teams that will implement them in the real world. Early involvement of the operations team is a good starting point for a successful handover. However, understanding complex operations from afar often leads to early production problems, and the travel costs of sending experts to different production sites can be significant.. In addition, internal frustration can result from a lack of understanding and cooperation during this crucial transition period, leading to delays and low morale. “I think it’s important to understand that there is usually some form of compromise when design changes are introduced late in the process,” says Scruggs.&nbsp;</p><p>He adds: “For us, it’s about improving quality down to every sub-assembly. With Hololight Space, our operations teams in different regions can see in Augmented Reality how each assembly is created in real time. They can see the critical points and we can identify where there may be mistakes or confusion; it’s a collaborative effort to get better quality from day one, using immersive technologies to our advantage.” By enabling better collaboration across sites and geographies, AR improves the quality and speed of production ramp-up, ensuring a smoother transition from design to operation. The ability to work remotely with AR technology, especially when multiple international locations are involved, greatly reduces travel-related costs and time. In an era where efficiency and communication are paramount, Hololight Space is proving to be a key tool in transforming the handover of operations into a seamless and streamlined process.</p><h2>How LNS Group Is Getting User Buy-in and Planning New Use Cases</h2><p>To successfully integrate Augmented Reality into the product development process and gain user acceptance, Jamie Towers suggests limiting user interaction. &nbsp;“We usually have an AR-trained member in the room to help with the manipulations, and then we hand the glasses over to the user to just experience the design in AR. There are some people who are never fully comfortable until they actually have something in their hands. But overall, our people are definitely impressed with the technology. They see the value in the technology.”And the next project is just around the corner. “We’re investing in immersive technologies, and it’s natural to keep using them. This time we made a prototype with one configuration, and we’re going to use Hololight Space to show our customer a second, completely different configuration without having to produce a second prototype. Wherever we can find an advantage, we will use immersive technologies to optimize our product development lifecycle,” concludes Towers.</p><p>Want to try Hololight Space for yourself? <a href="https://hololight.com/hololight-space-demo/" target="_blank">Contact us for a free trial.</a></p>

LNS Group, is using immersive technologies throughout its product development cycles. The company is reducing time-to-market by 3 months and saving $5,000 to $10,000 per prototype while improving product quality.


Industrial Augmented Reality-Driven Product Development Evolution

<p>So, what can you do to establish a strong foundation for success without compromising the end product and, thus, your customer experience? Continue reading to find out more.</p><p>There are several benefits that 3D printing offers for rapid prototyping, including:</p><ol id="isPasted"><li><strong>Speed -&nbsp;</strong>Speed is at the top of the list and very important when you are competing to get ahead of the market. 3D printing has rapid turnarounds compared to some other traditional manufacturing methods. This allows for quicker turnaround of iterations and overall project completion.</li><li><strong>Cost-Effective&nbsp;</strong>—There are no startup costs, and no expensive moulds or tools are required. This reduces the costs sometimes associated with rapid prototyping and makes it more accessible for small businesses and startups. Of course, variation in cost can be high. Some materials are more expensive than others, and the complexity of the part and the time taken to produce it will impact the cost.</li><li><strong>Complex Geometries</strong> —The complexity you can achieve with 3D printing is near limitless. Complex shapes and intricate details that may be difficult or impossible to achieve with traditional methods are possible with 3D printing.</li><li><strong>Customisation</strong> —3D printing enables easy customisation of parts and prototypes. Changes can be made quickly and efficiently, resulting in a more personalised product.</li><li><strong>Material Variety</strong> —The wide range of materials used for 3D printing allows for testing prototypes with many different material properties.</li><li><strong>Reduced Waste</strong> —As an additive process, the material is only used where needed, unlike its subtractive counterparts, which remove material from a block, leaving much waste.</li><li><strong>Functional Testing</strong> —Prototypes produced using 3D printing can be used for functional testing. This allows for the assessment of the design's performance as it would be in real-world conditions.</li><li><strong>Iterative Development</strong> – enables quick production of test prototypes, which is great for an iterative development process.</li><li><strong>Simplified Assembly&nbsp;</strong>—Complex assembled parts can be printed as a single part rather than multiple components, reducing the need for assembly.</li></ol><p>Of course, there are times when 3D printing may not be appropriate for your prototyping needs. Injection moulding has a wider range of materials, while CNC machining offers high precision, tight tolerances, and high-quality surface finishes. However, 3D printing is perfect for most early-stage prototyping. It can provide complex geometries, quick iterations, and low-volume production.</p>

Being first to finish is always top of the agenda, especially when getting your product to market. Those extra moments with less competition could make or break a brand and/or its product.

The Benefits of 3D Printing for Rapid Protoyping

<p id="isPasted">Our <em>Insight</em> video series will help you master digital manufacturing.</p><p>Every Friday we’ll post a new video – each one giving you a deeper <em>Insight</em> into how to design better parts. We’ll cover specific topics such as choosing the right 3D printing material, optimising your design for CNC machining, surface finishes for moulded parts, and much more besides.</p><p>So join us and don’t miss out.</p><p id="isPasted"><span contenteditable="false" draggable="true" class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable fr-active"><iframe src="https://fast.wistia.net/embed/iframe/ux935q0x3d" width="900" height="450" allowtransparency="true" frameborder="0" scrolling="no" class="wistia_embed fr-draggable" name="wistia_embed" allowfullscreen="" mozallowfullscreen="" webkitallowfullscreen="" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe></span><br></p><p id="isPasted"><strong>Transcript</strong></p><p>Hello and welcome to this week’s Insight.&nbsp;</p><p>Today we’re going to take a close look at cutting corners. But before you get too concerned, I’m talking about the corners on injection moulded parts.&nbsp;</p><p>Now I like a right angle the same as anyone else, but sometimes it can be a bit too sharp for its own good.</p><p><a href="https://www.protolabs.com/media/eymh3apg/implementing-corners-in-injection-moulded-parts-large.jpg" target="_blank" rel="noopener noreferrer">Image</a></p><p id="isPasted">As an engineering or product designer you need to be aware of the pitfalls of being too square when developing your parts for injection moulding. If you don’t have the right amount of corner rounding and filleting, then part accuracy, strength and aesthetics can suffer.</p><p id="isPasted">Generally, it’s important to have smooth rounded edges, but there are a number of factors that can affect even a well radiused part.</p><p>Some plastics are more forgiving of sharp cornered parts than others, so talk to your supplier.</p><p>The thickness of your walls will also play a role. Beefing up adjacent walls can absorb some of the stress that you get from sharp internal corners, but beware because that beefed up wall can cause other design issues.</p><p id="isPasted">And part geometry can be important. Some parts are simply more mouldable than others.</p><p>All of these factors can affect the amount of corner radius that you need on a part design, it’s a question of balancing them, because Injection moulding is a complex process.</p><p>But what about when you are sitting in front of your CAD? Well there are two types of radius that we need to think about: internal and external. Just so that you know, when I talk about filleting, I’m talking about radii that are found at the bottom of each compartment where the walls meet the floor of a box. &nbsp;You don’t want to make these corners too sharp, so put in a radius that is at least half as thick as the adjacent wall thickness.</p><p id="isPasted">As for the radii at the top of those walls, well they should be rounded to about one and a half times the thickness of the wall.&nbsp;</p><p>Why is this? Well it allows the molten plastic to flow more easily and gets rid of the residual stress that twists thin walled workpieces. It also prevents cracking that could lead to your part or product failing.</p><p>The material that you select can also make a difference. If you’ve used injection moulding before, then you may have seen gaps along the top of some of the compartments or on the outside of a case. It’s almost as if there wasn’t enough plastic to complete the part. But It’s not because your supplier has been skimping on you, the culprit is more likely to be the raw material itself.</p><p>When you force plastic through an injection mould, it does not behave like an amorphous easygoing blob. It creates long chains of molecules that link with adjacent molecules and they don’t like being cramped into a tight corner or having to flow around a sharp edge caused by posts or wall intersections.</p><p id="isPasted">It means that the material might not reach every nook and cranny in your mould cavity and you are left with some gaps.&nbsp;</p><p>Even if the material does flow where it’s meant to, the stress caused by all that molecular bending and twisting can result in warp and bow on the moulded part.</p><p id="isPasted">Obviously neither of these scenarios are great.</p><p>There are two things that you can do. Generally, the problem is worse for glass- and fibre-filled materials because their greater strength and molecular integrity make them less likely to go with the flow than unfilled plastics.</p><p>The second one is to get the mould design right, proper radiusing will go a long way to avoiding this.</p><p id="isPasted">You also need to realise that there are certain machining limitations that can prevent you having the sharp corner that you want. The internal corners in any mould cavity can’t be smaller than the end mill used to machine them.</p><p id="isPasted">Now you can get around this by using other manufacturing methods such as electrical discharge machining, but this is slow and will cost you more money. Plus of course you run the risk of the complications that I’ve already talked about when it comes to the injection moulding itself.</p><p>Moving on, I mentioned about beefing up your walls to help you get sharper corners… well it’s not just about making them thicker, because this can lead to sink, shrink and bubbles.&nbsp;</p><p>You are far better to strengthen the wall by introducing a honeycomb pattern on thin sections or have a series of short vertical ribs to help prevent bending.&nbsp;</p><p id="isPasted">Now if all of this rounding and filleting sounds like a right hassle, don’t worry; your CAD system should help and your supplier should pick up on any potential problems when they check your design using their design for manufacturability analysis.</p>

Your masterclass in product design and development

Injection Moulding - Don't Be Too Sharp

<p dir="ltr" id="isPasted">An interesting observation from RPWORLD’s experienced manufacturing engineers: Over 10 years ago, different custom mechanical parts often had a mix of different strict and loose tolerances. However, in recent years, mechanical parts of different applications frequently have very strict tolerances and high precision, even for surfaces where high dimensional accuracy and surface quality are not crucial. This reflects industrial progress, but actually some of these stringent requirements are unnecessary. Today, let's discuss a major misunderstanding about CNC machining tolerances.</p><h2 dir="ltr">A Misunderstanding about CNC Machining Tolerances</h2><p dir="ltr">People often believe that tight tolerance can improve product quality. Actually, tight part tolerances only indicate a high production quality for individual parts, and do not directly equate to higher product quality. Product quality is ultimately presented through the assembly of parts. However, the tighter the tolerances for parts, the higher the manufacturing costs and product costs. For instance, an overly stringent tolerance might require that parts go to a secondary grinding or EDM operation for completion, unnecessarily increasing costs and lead-time. The relationship between the machining cost and part is shown in the following figure.</p><p dir="ltr">Meanwhile, tolerances that are “too loose” or that aren’t in line with those of mating parts can make assembly impossible, leading to required rework, or in the worst case, making the finished product unusable. Therefore, while meeting product function and quality’s requirements, the tolerance requirements for parts should be reasonably set to reduce product manufacturing costs.</p><h2 dir="ltr">How to Set Reasonable Part Tolerance for Product Design?</h2><h3 dir="ltr">1. Design Reasonable Gap</h3><p dir="ltr">In the assembly relationships of parts, there are situations where the planes of parts are in contact and tightly fit together, leaving no gaps between the planes. In other cases, a certain gap needs to be designed between the planes to prevent assembly interference or to ensure that the assembled product dimensions remain within specifications. Generally, as long as it does not affect the product's function and quality, the gap should be as large as possible.</p><h3 dir="ltr">2. Simplify Assembly Relationships</h3><p dir="ltr">Simplifying assembly relationships reduces the number of dimensions in a tolerance chain, thereby decreasing cumulative tolerance. In a dimension chain, fewer dimensions lead to smaller cumulative tolerance. For critical assembly relationships, adjustments should be considered in the initial design phase to simplify assembly and avoid requiring too many parts with strict tolerances, ultimately reducing cumulative tolerance.</p><h3 dir="ltr">3. Use Positioning Features</h3><p dir="ltr">When designing parts with assembling relationships, adding positioning, as illustrated in below. This method enables parts to be accurately assembled into products. In product design, it is only necessary to control the process tolerances of dimensions related to the locating features, allowing looser tolerance requirements for other less critical dimensions.</p><h3 dir="ltr">4. Use Points or Lines for Planar Fits</h3><p dir="ltr">When two parts have a plane-to-plane fit and relative motion, either during assembly or use, a point or line to plane fit can be used instead. This prevents plane deformation or high surface roughness from hindering smooth movement, allowing for more relaxed flatness and surface roughness tolerances.</p><p dir="ltr">The above are some examples of designing appropriate tolerances for CNC machined parts. Want to know more about the biggest myth about tolerances? We’re here to support your project from prototyping to production, whatever the tolerance requirements. RPWORLD provides all your CNC milling and turning needs. We always have manufacturing engineers available to assist with any questions. Ready to start your next project? Contact us now.</p>

Let's discuss a major misunderstanding about CNC machining tolerances.

Reasonable CNC Machining Tolerances - Balancing Precision and Cost

<p id="isPasted">In product development, parts or products generally move through three phases of evolution: first, prototyping; second, low-volume production; then third—and final—serial production. In each case, the goal is to move smoothly from each development phase to the next, refining the product and its manufacturability. Overall, the objective is to minimise the total time and cost of the overall process, bringing a product from the initial concept to serial production smoothly and efficiently and as quickly and cost-effectively as possible. 3D printing is often a great entry route to prototyping plastic parts mainly because it is a quick, flexible, and cost-effective process. But what happens once you are ready to move forward with your product development plan? Many product developers are successfully turning towards injection moulding, but not every project is suitable for every production method. To decide whether injection moulding is ideal for you, you need to consider several factors:</p><p><strong>Cost</strong></p><p>Many factors affect the cost of a part; a significant amount usually is tooling for injection moulding. Components are created by injecting molten plastic resin into the negative cavity of a tool, also known as a mould. If tooling is a big investment, it will only be economical on a cost-per-part basis if you produce many identical parts, often numbering in the hundreds or thousands. Another factor will be the time to make each part and the number that you will need. Your final decision may come down to balancing the number of parts you need against the cost of tools.</p><p>At Protolabs, we have reduced this cost and time by streamlining our processes so that you can have tooling in just 1 to 15 days. This is an excellent option if you need volumes or a batch quantity of anything from a few hundred to 150,000 parts. Our solution is often used in industry for mass customisation of parts if you want to segment your product for different market segments. With 3D printing, there is no tooling; you can print what you design and can print almost any design you want. It makes sense if you want a few hundred parts or need several different versions of those parts.</p><p><strong>Design</strong></p><p>Better design can reduce any production method's costs, so a deep understanding of the final manufacturing process is vital when prototyping. If your component isn't complex and has a fairly simple geometry, then injection moulding will be more cost-effective as volumes increase. Conversely, 3D printing is a better option if you require complex geometry.</p><p>Surface finish is an important consideration when choosing a production method. 3D printing creates parts by layering material each step at a time so the finished surface can be ridged. Although you can use vapour smoothing to level out the surface leading to a smooth finish, it is a secondary operation and will need to be factored into your thoughts. Injection moulding creates parts with a smooth surface because the material is poured into a single layer to create a virtually uniform smooth surface finish.</p><p><strong>Material</strong></p><p>The material you want your product to consist of should be a significant factor in your decision-making. The material choice can affect not only the cost of your product but also its performance and longevity. Only some production methods offer many material types; for example, more materials are available using injection moulding than 3D printing.</p><p>At Protolabs, we offer 100s of different resins for injection moulding, compared to 14 options as a standard for 3D printing. You can order more options for both processes, but again these are additional steps in your journey that you will need to consider.</p>

As manufacturing technologies evolve, they present new opportunities for manufacturers throughout the product life cycle. More and more product developers are choosing to pivot from one production method to another or are transitioning between them to suit their needs.

3D Printed Plastic: Prototypes: What's Next?

<section id="isPasted"><p>The design and development of Printed Circuit Board (PCB) prototypes is the first step toward creating new electrical products. As engineers push the boundaries of hardware technology, the complexity of PCBs increases, necessitating the integration of specific features to streamline debugging, ensure functionality, and facilitate efficient production testing.</p><p>This article discusses the essential features you should include in your next PCB assembly prototype to enhance its debugging, testing, and general reliability.</p><h2></h2><h3>Debugging Features</h3><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1720616240845-1720616240845.png" alt="2klahksdjf" class="fr-fic fr-dii"><h5>1.1 Debug Headers</h5><p>The inclusion of debug headers in PCB prototypes offers a direct gateway to the board's heart, enabling engineers to connect easily to and interact with debugging interfaces.</p><p>These features are instrumental in diagnosing issues at an early stage and ensuring the prototype’s functionality. Every microcontroller requires its own specific debug hardware and connector part number. Check that there is enough room around the debug connector to ensure clearance to connect and disconnect the typical ribbon cable.</p><p>If you don’t have room for a full-size debug connector look into the <a href="https://www.tag-connect.com/" target="_blank">Tag Connect</a>, which is a space-optimized, pogo-pin-style cable that eliminates the need for bulky traditional connectors. This approach saves valuable board space and simplifies the debugging process, making it more efficient and less intrusive. You may need to develop your own “conversion” boards that adapt your debug hardware to the tag connect cable.</p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1720616242074-1720616242074.png" alt="3buoywe4g" class="fr-fic fr-dii"><h5>1.2 Heartbeat and Indicator LEDs</h5><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1720616242010-1720616242010.png" alt="4uyitftrd" class="fr-fic fr-dii"><p>A useful feature to add to your microcontroller-based prototype is an LED hooked up to a GPIO pin on the microcontroller. Typically called a “Heartbeat” indicator, this LED can be used as your first “blinky” or “Hello World” that runs on the microcontroller. This LED can be repurposed later to indicate which firmware routines or interrupts are running on the microcontroller.</p><p>Many active components and ICs have indicator signals like “power good” and “status”. Putting indicator LEDs on these signals makes debugging problems much easier. Instead of having to hook up a meter or logic analyzer you can visually see what is going on.</p><p>Similar to the indicator LEDs, putting LEDs on power rails makes for quick recognition if the problem you are trying to solve is power-related or not. For extra credit, have the indicator LEDs go through their own common net connected to a jumper so you can disconnect them to measure system current more accurately.</p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1720616242385-1720616242385.png" alt="5yghjbxf" class="fr-fic fr-dii"><h5>1.3 Swaperoo Resistors</h5><p>Ever get a serial bus UART TX and RX lines backwards? Yeah, me neither. Do both chips’ UART lines connect TX -&gt; TX, or is it TX -&gt; RX? The world may never know till you make that prototype. In the unfortunate event that you do cross these two signals, having a way to easily swap the signal connections is useful on prototypes. Putting two zero-ohm resistors next to each other and being able to rotate and cross the signals might save your PCB prototype one day.</p><h2></h2><h3>Testing Enhancements</h3><h5>2.1 Test Pads</h5><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1720616242454-1720616242454.png" alt="6hqniujnk" class="fr-fic fr-dii"><p>Test pads are a critical feature for any PCB prototype, providing accessible points for measuring electrical signals. Integrating test pads into the PCB design early on ensures a smoother transition from prototyping to production by playing a pivotal role in the production testing phase, allowing for thorough checks of circuit functionality in a more automated fashion.</p><p>If you have PCB real estate we like to use Keystone 5018 SMT Test points. These unique test points are placed on an SMT pad and feature a ring that allows more secure mounting of test clips. When you move your product to production, this component can just be marked as DNP (do not place) which leaves a test point that an in-circuit tester can easily contact.</p><h5>2.2 Signal Integrity Probing</h5><p>Designing PCB prototypes with dedicated points for signal integrity testing is crucial in today’s high-speed electronics landscape. These testing points allow for the assessment of signal integrity, identifying potential issues that could compromise the prototype's performance. Placing additional ground reference points near these critical test points will ensure your test equipment is picking up less noise and you can ensure that the prototype adheres to the required standards for signal quality and reliability.</p><h5>2.3 Accessibility for Test Equipment</h5><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1720616242549-1720616242549.png" alt="7niy3vbj" class="fr-fic fr-dii"><p>Easy accessibility for test equipment is paramount in PCB prototype design. By designing the board with connectors that seamlessly integrate with test tools, engineers can quickly and efficiently hook up their equipment directly to the PCB. This design consideration speeds up the testing process and reduces the risk of damage and shorting to the board by minimizing the need for makeshift connections.</p><p>How many times have you struggled with keeping test clips attached while moving a prototype or having a multimeter test probe slip or unclip itself during a test? Integrate your testing tools and equipment!</p><h5>2.3 Expose Those Vias</h5><p>So you have placed test points on every signal you think you may need to probe. Think that is enough? Leave those PCB vias untented and uncovered so they can be used as test points in a pinch. You will thank yourself later.</p><p><strong>Want to learn more about testing methods? Read <a href="https://www.macrofab.com/blog/circuit-board-testing-methods/" target="_blank">Circuit Board Testing Methods: What You Need to Know</a> now.</strong></p><h2></h2><h3>Power and Sub System Management</h3><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1720616242623-1720616242623.png" alt="8niownkjd" class="fr-fic fr-dii"><h5>3.1 Jumper Headers on Power Rails</h5><p>Jumper headers inserted in series on power rails offer a simple solution for power management within the PCB prototype. This feature allows for quick segmentation and troubleshooting of power supplies without necessitating circuit modifications. Engineers can gain flexibility in diagnosing power supply issues and have the ability to measure current draw through each power system.</p><p>I like to implement this by having a standard 2-pin 2.54mm header that a shunt can go across. Then in parallel to this header, I like to put a zero ohm resistor. If everything is good with the system I can place a zero ohm resistor and not worry about the through-hole component and shunt.</p><h5>3.2 Sub-system Segregation</h5><p>Expand the previous idea to more of your system. Engineers can add the capability to test subsystems individually, significantly enhancing the prototype's diagnostic capabilities. If your new switching power supply is not working you can easily bypass it and use a lab power supply to bring up and validate the rest of the sub-systems. Don’t let a small, non-functioning part of your prototype prevent you from getting more data about your design.</p><h2></h2><h3>Thermal Management</h3><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1720616242822-1720616242822.png" alt="9noiyuhj" class="fr-fic fr-dii"><h5>4.1 Effective Heat Management</h5><p>Effective thermal management is essential for maintaining the integrity and longevity of PCB components. Including thermal testing points in the prototype design enables engineers to monitor and ensure the board operates within safe temperature conditions. This foresight prevents overheating, thereby protecting components from damage and potentially extending the prototype’s lifespan.</p><h2></h2><h3>Physical Design Philosophy</h3><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1720616243115-1720616243115.png" alt="10bniljdklnfl" class="fr-fic fr-dii"><h5>5.1 Prioritize Functionality Over Form</h5><p>When developing PCB prototypes, engineers are advised to prioritize functionality and ease of debugging over form factor considerations. This design philosophy ensures that the prototype is both testable and reliable, and also adaptable to subsequent iterative improvements. Emphasizing debugging and functional validation in the prototype stage lays a solid foundation for a seamless transition to production, ultimately resulting in a high-quality product.</p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1720616242947-1720616242947.png" alt="11niosnfjkg" class="fr-fic fr-dii"><h5>5.2 PCB Mounting Holes</h5><p>Well-placed and appropriately sized PCB mounting holes are integral to the design of a robust PCB assembly prototype. These elements are pivotal to mounting the PCB physically as well as ensuring its structural stability and electrical safety throughout prototype testing. Having the prototype securely mounted to a base prevents damage to components on the backside when placed or slid around on your bench or desk for testing.</p><p>Keep in mind how you are going to use the mounting hole. Make sure to leave enough clearance for the head of the fastener and the tool required. We have a more <a href="https://www.macrofab.com/blog/attaching-your-project-to-things-mounting-holes-and-what-to-watch-out-for/" target="_blank">in-depth article about PCB mounting holes on our blog</a>.</p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1720616243255-1720616243255.png" alt="12niuonjk" class="fr-fic fr-dii"><h5>5.3 Utilize All Possibilities</h5><p>Foresight can be the difference between a straightforward modification and a complete redesign. One such forward-thinking practice involves breaking out unused pins on components and integrated circuits to small test points or headers. This approach maximizes the utility of available board resources and provides an invaluable contingency for future modifications or debugging efforts.</p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1720616243360-1720616243360.png" alt="13bnijkdf" class="fr-fic fr-dii"><p>By allocating small, accessible test points for these unused components, engineers ensure they have the flexibility to implement a "greenwire patch" should the need arise. This technique, involving the addition of temporary wire connections to modify circuit behavior, fix issues, or implement new features, can be a lifeline in the development process. It allows for rapid on-the-fly adjustments without the need for re-fabricating the PCB, significantly accelerating development timelines and reducing costs.</p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1720616243420-1720616243420.png" alt="14iuwhenitujk" class="fr-fic fr-dii"><h5>5.4 Meta-Information and Serialization</h5><p>Embedding meta information directly onto the PCB can substantially streamline both the manufacturing process and subsequent troubleshooting phases. Incorporating details like the version number of the PCB and picking a dedicated solder mask color for prototypes versus production directly into the design, as well as encoding hardware identification (ID) with values that your firmware can read, serves as an ingenious method to convey crucial information about the hardware.</p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1720616243485-1720616243485.png" alt="15ljjmiorkjngm" class="fr-fic fr-dii"><p>Serialization is not just for production. Having serial numbers on prototypes allows you to closely document modifications, tests, and the lifecycle of your prototypes. Recording your steps in getting your prototype up and running will help you analyze the specific steps that got the PCB operational. If board space is available, leave a 0.5” x 1.0” area for a serialization sticker. The smallest normal PCBA serialization stickers run 0.25”x 0.25” but require more specialized label prints to handle the smaller stickers. Of course, good ole’ sharpie markers work as well!</p><p>This practice of embedding meta-information enhances the PCB's self-documenting capabilities, making it easier for engineers and technicians to access essential data, streamline the product lifecycle management, and reduce the potential for errors during assembly or maintenance, thereby embodying a blend of creativity and practicality in PCB design.</p><h2></h2><h3>Conclusion</h3><p>Incorporating the features discussed into your next PCB assembly prototype can significantly enhance its debuggability, testability, and reliability. By focusing on debugging features, production testing enhancements, power management, accessibility for test equipment, signal integrity, and thermal management, engineers can address critical aspects of PCB design that influence the prototype’s overall performance and quality, before your PCB fabrication begins.</p><p>By prioritizing functionality and designing for easy debugging, you can create cost-effective PCB prototypes that are both innovative and strong enough to handle the realities of the production process. This focus on practicality, from the beginning, will help ensure your design can be built efficiently without needing expensive rework.</p></section><h4>Ready to Start Your Next Prototype?</h4><p><a href="http://factory.macrofab.com/quick_quote/?utm_source=linkedin&utm_medium=ppc&utm_content=041124_demomfvstrad_demo_static" target="_blank">GET AN INSTANT QUOTE NOW!</a></p>